U.S. patent application number 10/423362 was filed with the patent office on 2004-01-22 for decorative coating composition for solid substrates.
Invention is credited to Kupcakova, Zdenka, Milic, Richard.
Application Number | 20040014864 10/423362 |
Document ID | / |
Family ID | 29269748 |
Filed Date | 2004-01-22 |
United States Patent
Application |
20040014864 |
Kind Code |
A1 |
Milic, Richard ; et
al. |
January 22, 2004 |
Decorative coating composition for solid substrates
Abstract
A coating composition comprising (a) 10 to 60 wt. % of one or
more hydroxy-, carboxy- and/or amino-functionalized solid resins
selected from the group of methacrylic resins, acrylic resins,
polyester resins, polyurethane resins, epoxy modified resins with
linear, branched or star structure, (b) 5 to 40 wt. % of one or
more crosslinking agents for component (a), (c) 5 to 70 wt. % of a
filler, such as, aluminum hydroxide, (d) 0 to 40 wt. % of a ground
polymer material, (e) 0 to 35 wt. % of organic solvents, (f) 0.01
to 15 wt. % % of additives and pigments and (g) 0 to 30 wt. %
reactive thinners.
Inventors: |
Milic, Richard; (Hradec
Kralove, CZ) ; Kupcakova, Zdenka; (Pardubice,
CZ) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY
LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1128
4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
29269748 |
Appl. No.: |
10/423362 |
Filed: |
April 25, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10423362 |
Apr 25, 2003 |
|
|
|
10146162 |
May 15, 2002 |
|
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Current U.S.
Class: |
524/437 ;
427/385.5 |
Current CPC
Class: |
C08G 18/4615 20130101;
C09D 5/28 20130101; B05D 3/00 20130101; C08G 18/6229 20130101; C09D
7/40 20180101; C08G 18/792 20130101; C08G 18/798 20130101; C09D
5/29 20130101; C08G 18/6279 20130101; C09D 175/06 20130101; C08G
18/4063 20130101 |
Class at
Publication: |
524/437 ;
427/385.5 |
International
Class: |
B05D 003/02; C08K
003/10 |
Claims
What is claimed:
1. A coating composition comprising (a) 10 to 60 wt. % of a
functionalized solid resin having functional groups selected from
the group consisting of hydroxy-, carboxy- amino- and any mixtures
thereof and wherein the functionalized solid resins are selected
from the group consisting of methacrylic resins, acrylic resins,
polyester resins, polyurethane resins, epoxy modified resins with
linear, branched or star structure, (b) 5 to 40 wt. % of at least
one crosslinking agent for component (a), (c) 5 to 70 wt. % of
filler material, (d) 0 to 40 wt. % of a ground polymer material,
(e) 0 to 35 wt. % % of organic solvents, (f) 0.01 to 15 wt. % of
additives and pigments and (g) 0 to 30 wt. % reactive thinners.
2. The coating composition according to claim 1 wherein component
(a) comprises one or more resins selected from the group consisting
of acrylic resins, methacrylic resins, polyester resins and resins
with star structure.
3. The coating composition according to claim 1 wherein component
(b) is selected from the group consisting of isocyanurates,
biurets, uretdions and allofanates of 1,6-hexane diisocyanate.
4. The coating composition according to claim 1 wherein component
(c) is aluminum hydroxide.
5. The coating composition according to claim 1 where component (d)
comprises 2 to 30 wt. % polymethyl methacrylate containing
filler.
6. The coating composition according to claim 1 wherein the
composition is a flowable liquid composition and wherein (b) the
crosslinking agent for component (a) comprises a polyisocyanate
selected from the group consisting of blocked polyisocyanates and
unblocked polyisocyanates.
7. The coating composition according to claim 6 wherein component
(a) comprises one or more resins selected from the group consisting
of acrylic resins, methacrylic resins, polyester resins and resins
with star structures.
8. The coating composition according to claim 6 wherein component
(b) is selected from the group consisting of isocyanurates,
biurets, uretdions and allofanates of 1,6-hexane diisocyanate
9. A coating composition comprising (a) 10 to 60 wt. % of a
functionalized solid resin having functional groups selected from
the group consisting of hydroxy-, carboxy- amino- and any mixtures
thereof and wherein the functionalized solid resins are selected
from the group consisting of methacrylic resins, acrylic resins,
polyester resins, polyurethane resins, epoxy modified resins with
linear, branched or star structure, (b) 5 to 40 wt. % of at least
one crosslinking agent selected from the group consisting of
hydroxyl, carboxyl, amide or amino group containing crosslinking
agents, cycloaliphatic aliphatic or aromatic polyisocyanates, epoxy
group containing crosslinking agents, and carboxy-functional
polymers; (c) 5 to 70 wt. % of filler material, (d) 0 to 40 wt. %
of a ground polymer material, (f) 0.01 to 15 wt. % of additives and
pigments.
10. The composition according to claims 9 wherein component (a)
comprises one or more resins selected from the group consisting of
acrylic resins, methacrylic resins, polyester resins and resins
with star structure.
11. The composition according to claims 9 wherein component (b) is
selected from the group consisting of isocyanurates, biurets,
uretdions and allofanates of 1,6-hexane diisocyanate.
12. The composition according to claims 9 wherein component (c) is
aluminum hydroxide.
13. The composition according to claims 9 wherein component (c)
comprises 10 to 60 wt. % of the coating composition.
14. The composition according to claims 9 wherein component d)
comprises 2-30 wt. % polymethyl methacrylate containing filler.
15. The composition according to claim 14 wherein component d)
consists of about 40 wt. % polymethyl methacrylate, and 60 wt. % of
aluminum hydroxide, colorants, and other additives at low
levels.
16. The composition according to claim 6 wherein the amount of the
organic solvents is from 10 to 35 wt. %.
17. A process for coating a substrate which comprises applying a
one-coat layer on a substrate using a coating composition according
to claim 1 and curing said coating.
18. A process for coating a substrate which comprises applying a
one-coat layer on a substrate using a coating composition according
to claim 9 and curing said coating.
19. A process for forming a multi-layer coating which comprises
applying several coating layers to a substrate being applied from
the coating composition according to claim 1 and curing said
coating layers.
20. A process for forming a multi-layer coating which comprises
applying several coating layers to a substrate being applied from
the coating composition according to claim 9 and curing said
coating layers.
21. A process for forming a coating layer as one-coating layer of a
multi-layer coating which comprises applying to a substrate a
coating layer selected from the group consisting of externally
pigmented top coat layer and transparent clear coat layer said
coating layer being applied from the coating composition according
to claim 1 and curing said coating layer.
22. A process for forming a coating layer as one-coating layer of a
multi-layer coating which comprises applying to a substrate a
coating layer selected from the group consisting of externally
pigmented top coat layer and transparent clear coat layer said
coating layer being applied from the coating composition according
to claim 9 and curing said coating layer
23. A substrate coated with a cured layer of the coating
composition according to claim 1.
24. A substrate coated with a cured layer of the coating
composition according to claim 9.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part application of
Ser. No. 10/146,162 filed May 15, 2002.
FIELD OF THE INVENTION
[0002] The invention relates to a coating composition for a
substrate that provides a decorative surface having a stone, marble
or granite-like effect and unique aesthetics and the resulting
coated substrate can be used, for example, as building materials,
for counter tops, wall panels, furniture, and for various other
articles.
BACKGROUND OF THE INVENTION
[0003] Coatings for substrates used in industrial and house-keeping
fields, e.g., for surfaces in kitchens, baths and stores or for
wall panels, furniture and other articles in home and business
sectors, can have a solid color or stone, granite, or marble-like
or other unique appearance.
[0004] Such coatings comprise a filled polymer composition that is
cured at ambient temperature or can be force-dried at elevated
temperature. The coated articles can be costly to produce and
difficult to transport and to install due to their heavy and
brittle properties, e.g., they are fragile and easily chipped,
broken or abused. The breakage rate at the required thickness makes
these articles expensive.
[0005] Examples for known coatings and coated substrates are
described as follows: JP 10128911, JP 8295548, JP 55126583, which
relate to coating layers based on thermoplastic resins, such as,
polyester, acrylic resins, and reinforced fiber.
[0006] U.S. Pat. No. 5,789,032 relates to a curable composition
including polyester resin and filler useful for the production of
stone, marble, or granite effect coatings. A vibration action is
needed to level the composition and to form an equable coating on
the surface.
[0007] The present invention satisfies the demand for a decorative
and robust coating for interior and exterior surfaces, especially
for horizontal and vertical working tops, panels; furniture in
homes, offices or industrial buildings; counter and dining tables,
counter tops, floors; architectural facing of buildings and various
articles (lamps, vases, picture frames, etc.) of all types. The
coating composition is a highly filled composition comprising a
selected solid resin, a filler, decorative granules or other
aesthetic materials, and special additive systems.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to a high-filled coating
composition comprising
[0009] (a) 10 to 60 wt % of one or more hydroxy-, carboxy- and/or
amino-functionalized solid resins selected from the group of
methacrylic resins, acrylic resins, polyester resins, polyurethane
resins, epoxy modified resins with linear, branched or star
structure,
[0010] (b) 5 to 40 wt. % of one or more crosslinking agents for
component (a),
[0011] (c) 5 to 70 wt. % of a filler material,
[0012] (d) 0 to 40 wt. % of a ground polymer material,
[0013] (e) 0 to 35 wt. % of organic solvents,
[0014] (f) 0.01 to 15 wt. % of additives and pigments and
[0015] (g) 0 to 30 wt. % reactive thinners.
[0016] The composition can be formed as a flowable liquid or as a
solid composition without organic solvent and reactive thinners and
is cured after application on the substrate. The cured coating can
be sanded and polished; and the final article can be cut into a
desired shape if necessary.
[0017] Relating to the flowable liquid composition the component
(b) comprises one or more polyisocyanates selected from the group
consisting of blocked and unblocked polyisocyanates.
[0018] Relating to the solid composition without organic solvents
and reactive thinners, the component (b) comprises one or more
crosslinkers, such as hydroxyl, carboxyl, amide or amino groups
containing crosslinkers, cycloaliphatic, aliphatic or aromatic
polyisocyanates, epoxy groups containing crosslinkers or
carboxy-functional polymers.
[0019] The appearance of the final coating prepared from the
coating composition according to the invention is characterized by
a solid and/or a stone-, granite-, marble-like appearance or other
special aesthetic appearance. The articles produced with the
coating composition according to the invention can be used as
decorative surfaces, e.g., countertops, wall panels, for furniture,
for floors, and for all types of various articles. The coatings and
the coated products are robust and stable and are workable and
repairable. The coatings can be applied in a factory or on
location. They have an appearance of stone, cultured marble or
granite, such as, the material Corian.RTM.. The coating composition
can be applied on a vertical panel without sagging within a dry
thickness range from 25 to 30 mils (0.635 to 7.62 mm) by a single
application, and the composition can be characterized as a low VOC
(Volatile Organic Content) composition.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The resins of component a) are functionalized by hydroxy
and/or carboxy and/or amino groups. The OH-value and the COOH-value
can be, for example, in the range from 10 to 300. Particularly
preferred, are hydroxy and/or carboxy functionalized resins having
an OH-value in the range of 10 to 300 and a carboxy value of 10 to
50. If amino groups are present, hindered secondary amino groups
are preferred.
[0021] The functionalized resins can be manufactured by
polymerization reactions known by a skilled person, especially by a
radical polymerization but also, e.g., by a polymerization reaction
caused by a photochemical reaction or by electromagnetic radiation.
Group Transfer Polymerization can also be used.
[0022] The resins can be linear, branched or star structured.
[0023] The resins, component a), are contained in the range from
about 10 to 60 wt. %, preferably from about 10 wt. % to 30 wt. %,
based on the coating composition.
[0024] Suitable monomers or co-monomers for the manufacture of the
acrylic and methacrylic polymers of component a) may be, e.g.,
acrylates, methacrylates, methyl methacrylates, styrene,
acrylonitrile, vinyl acetate, butadiene, including monomers, such
as, acrylic acid, methacrylic acid, itaconic acid, maleic acid,
crotonic acid and/or amides. To obtain the functionalized
polymethacrylics and polyacrylics, suitable monomers can be
incorporated into the polymer, e.g., carboxy-functionalized
monomers, such as, maleic acid, acrylic acid and methacrylic acid,
and, for example, hydroxy-functionalized monomers, such as, hydroxy
acrylates, hydroxy methyl acrylates, propylene glycol
methacrylates, butanediol monoacrylates and the like.
[0025] Suitable monomers or co-monomers for the manufacture of the
functionalized polyesters may be, for example, neopentyl glycol,
cyclohexanedimethanol, 1,6 hexanediol, trimethylolpropane,
pentaerythritol, phthalic anhydride, isophthalic acid,
hexahydrophthalic anhydride, adipic acid, azelaic acid and dimer
fatty acids.
[0026] The polyesters can be, for example, linear, branched, star
structured, chemically modified by urethanes, silicones, styrene,
acrylics, epoxide, and the range of the OH value can be 10 to
300.
[0027] Star resins may be used as component a) and are oligomers
with a star structure, which have 3 to 6 arms. Oligomers are
prepared by reaction of trimethylolpropane, pentaerythritol or
other multifunctional compounds with, e.g., compounds containing
glycidyl groups. They include polyester bonds and both primary and
secondary hydroxyl groups.
[0028] As component a) one or more acrylic, methacrylic, polyester
and/or star polymers are preferred.
[0029] The crosslinking agents, component b), of the coating
composition are present in the range from about 5 to 40 wt. %,
preferably from about 5 wt. % to 20 wt. %, based on the coating
composition.
[0030] Examples of polyisocyanates that may be used as component b)
are in the free or blocked form as crosslinking agents and may
include triisocyanates, diisocyanates, and cycloaliphatic
diisocyanates, such as, 1,6-hexane diisocyanate, trimethylhexane
diisocyanates, 1,12-dodecanediisocyanates, cyclohexane
diisocyanates, isophorones, diisocyanates with cyclohexylmethane
diisocyanates or mixtures thereof, and polyisocyanates derived from
such diisocyanates, for example, those containing hetero atoms in
the radical linking the isocyanates groups. Examples thereof
include polyisocyanates containing carbo diimide groups,
isocyanurate groups, urethdiol groups, urethane groups and/or
biuret groups.
[0031] Suitable blocking agents for the polyisocyanate crosslinking
agents described above may include the conventional, for example,
CH-acidic, NH--, SH-- or OH-- functional blocking agents. Examples
include acetyl, acetone, acetoacetic acid acyl esters, valonic acid
diacyl esters, aliphatic or cycloaliphatic alcohols, oximes,
lactams, imidacoles, pyracoles.
[0032] Isocyanurates, biurets, uretdions, or allofanates of
1,6-hexane diisocyanate are the preferred compounds of component
b).
[0033] Examples of other crosslinkers that can be used as component
b) are crosslinkers containg reactive groups, such as hydroxyl,
carboxyl, amide or amino groups; cycloaliphatic, aliphatic or
aromatic polyisocyanates, crosslinkers containing epoxy groups,
carboxy-functional polymers that may be used as component (b) are,
for example, dicyandiamide and derivatives thereof; carboxylic
acids or anhydrides thereof, triglycidyl isocyanurates,
polyglycidyl ethers based on diethylene glycol,
glycidyl-functionalized (meth)acrylic copolymers, and dicarboxylic
acids having 10 to 12 carbon atoms.
[0034] The coating composition according to the invention contains
a filler material as component c). The content of this filler
material component is from 5 wt. % to 70 wt. %, preferably 10 wt. %
to 60 wt.%, based on the coating composition. Examples of such
filler materials are aluminum hydroxide, also known as alumina
trihydrate, Al.sub.2O.sub.33 H.sub.2O, calcium carbonate
(CaCO.sub.3), silica (SiO.sub.2), magnesium hydroxide
(Mg(OH).sub.2), barium sulfate (BaSO.sub.4), clays, talcs, alumina
monohydrate (Al.sub.2O.sub.3H.sub.2O) or polymeric fillers.
Preferably, aluminum hydroxide (Al.sub.2O.sub.3.3 H.sub.2O) is used
as component c).
[0035] The component d) is a small-grained solid material, which is
different from component c), and is a ground polymer material. The
content of this component d) is from 0 wt. % to 40 wt. %,
preferably 2 wt. % to 30 wt. %, based on the coating
composition.
[0036] This material can be based on polymethyl methacrylate
(pMMA), crosslinked unsaturated polyester, epoxide or other
polymeric material--filled or unfilled.
[0037] This material can be ground or calendered by mills, grinders
or calender to small particles like granules, crunchies, flakes,
and powder particles. The material can be toned in different colors
or in one color. Examples of additives used in this material are,
e.g., colorants, antioxidants, catalysts, light stabilizers, and
also fillers. One example for the component d) is a filled polymer
material consisting of about 40% of polymethyl methacrylate, of
about 60% of aluminum hydroxide, colorants, and other additives at
low levels, for example, known under the name of Corian.RTM., which
is a product of DuPont.
[0038] Examples of organic solvents that may be used in the coating
composition according to the invention as component e) include
glycol ethers, such as, butyl glycol, butyl diglycol, dipropylene
glycol, dimethyl ether, dipropylene glycol monomethyl ether,
ethylene glycol dimethyl ether; glycol ether esters, such as, ethyl
glycol acetates, butyl diglycol acetates, methoxypropyl acetates;
esters, such as, ethyl acetate, butyl acetate, isobutyl acetate,
amyl acetate; ketones, such as, methyl ethyl ketone, methyl propyl
ketone, methyl isopropyl ketone, methyl isobutyl ketone, diisobutyl
ketone, methyl amyl ketone, cyclohexanone, isophorones; alcohols,
such as, methanol, ethanol, propanol, butanol; aromatic
hydrocarbons, such as, toluene, xylenes, Solvesso.RTM. 100 (mixture
of aromatic hydrocarbons with a boiling range from 155 to
185.degree. C.), Solvesso.RTM. 150 (mixture of aromatic
hydrocarbons with a boiling range from 182 to 202.degree. C.), and
aliphatic hydrocarbons.
[0039] The organic solvents are contained in the range from 0 to 35
wt. %, preferably in a range of 10 to 25 wt. %, based on the
coating composition, in the case of liquid compositions according
to the invention.
[0040] Solid compositions according to the invention do not contain
any organic solvent as component e).
[0041] The coating composition may contain conventional coating
additives in total amount up to 15 wt. % based on coating
composition ready for application, for example, leveling and
anticratering agents, defoamers, dispersing and wetting additives,
rheological modifiers, such as, pyrogenic silica, modified clays,
polyamides and urea group-containing reaction products of amines
(sagging control agents), catalysts, colorants, light stabilizers,
UV absorbers, antioxidants and the, like.
[0042] Depending on the intended use of the coating composition and
on the integrated components, the coating composition may be
unpigmented (transparent), translucent, or contain pigments. They
may therefore contain fillers, which are different from the
component c) and/or transparent, color imparting and/or special
effect-imparting pigments. Examples of inorganic or organic
color-imparting pigments include titanium dioxides, micronized
titanium dioxide, iron oxide pigments, carbon black, azo pigments,
phthalocyanine pigments, quinacridone or pyrrolopyrrole pigments.
Examples of special effect-imparting pigments include metallic
pigments, interference pigments, e.g., metal oxide coated metallic
pigments, e.g., titanium dioxide-coated or mixed oxide-coated
aluminum, coated mica, e.g. titanium dioxide-coated mica and
graphite effect like special-effect pigments. Examples of suitable
fillers include aluminum trihydrate, silica, aluminum silicates,
barium sulfates, calcium carbonates, and talc.
[0043] Optionally, any material may be added for a decorative
effect. Decorative additives, such as, crushed stones, gemstones,
metal flake or fillings, micas, seashells, pearls, colored or
transparent polymeric particles or fibers, mirrored particles and
pigments may be added in quantities according to taste or
fashion.
[0044] However, these quantities usually do not exceed 5% by
weight, preferably 2% by weight. The decorative additives may be
thoroughly mixed with the other components or placed on the
surface.
[0045] Liquid coating composition according to this invention may
contain reactive thinners as component (g) in the range of 0 to 30
wt. %, preferred in the range of 2 to 10 wt. %.
[0046] Examples for the thinners are ketimines, aminofunctional
compounds, such as, for example,
1-aza-3,7-dioxo-bicyclo-2,8-diisopropyl-5-ethyl(3.3- .0)octane and
also oxazolidine derivatives, such as, for example,
3-ethyl-2-methyl-2-(3-methylbutyl)-1,3-oxazolidine.
[0047] The use of oxazolidines is preferred.
[0048] Solid compositions according to this invention do not
contain any reactive thinners as component g).
[0049] The coating composition according to the invention may have
a uniform color, a stone-like and/or a special aesthetic.
[0050] The liquid coating composition according to the invention in
the state ready for application has a solids content, formed from
the resins solids and the optionally contained non-volatile
additives and optionally contained pigments, from 40 wt. % to 80
wt. %. The coating composition contains, as volatile constituents,
organic solvents as mentioned above.
[0051] The coating composition can take the form of a one-component
coating composition or a two-component composition. In case of a
two-component coating composition, one component contains the
resins of component a) and the other component contains the
polyisocyanates. The other components of the coating composition
according to the invention, that means the aluminum hydroxide, the
ground material, organic solvents, additives and thinners may be
presented in either one or in both of the two components.
Preferably they may be present in the component which contains the
resins of component a).
[0052] The coating composition according to the invention may be
used in the preparation of a one-layer coating on any substrates
of, for example, metal, plastic, or substrates composed of a mixed
construction of metal and plastic and of any other material, for
example, clay, tile, woven glass fiber, masonites and the like.
Substrates employed include also plywood, particle board,
medium-density fiber board (MDF board), tile board. These
substrates can be used as products, such as, existing and in place
counter tops, cabinets, wall panels, furniture, slab boards,
ceramic tile, high pressure laminate (HPL), low pressure laminate
and other such laminates, stainless steel, gypsum board, glass and
the like. The coating composition may also be applied directly over
ceramic tile/group installations in such a way that a seamless
surface is formed with tile-like appearance.
[0053] The coating composition according to the invention can be
applied directly on the untreated surface of a substrate, for
example, of a porous substrate. It is also possible to use the
coating composition according to the invention for a multi-layer
coating of the substrate whereby the multi-layer coating may
consist of several coating layers of the coating composition of the
invention. Smooth or glass like surface should be coated, for
example, by an 2-pack epoxy primer or other appropriate primer to
ensure proper adhesion of the coating composition according to the
invention. Preferably the coating composition is used as a direct
coating of the untreated surface of a porous substrate.
[0054] In the event the coating composition is used for outdoor
purposes, for example, on the exterior of a building, the
weatherability of the composition can be improved by the addition
of an ultraviolet light stabilizer or a combination of ultraviolet
light stabilizers in the amount of 0.1% to 5% by weight, based on
the weight of the composition. Such stabilizers include ultraviolet
light absorbers, screeners, quenchers, and specified hindered amine
light stabilizers. Also, an antioxidant can be added, in the amount
0.1% to 2% by weight, based on the weight of the composition.
[0055] Typical ultraviolet light stabilizers that are useful
include benzophenones, triazoles, triazines, benzoates, hindered
amines and mixtures thereof. Specific examples of ultraviolet
stabilizers are disclosed in U.S. Pat. No. 4,591,533. Typically
useful hindered amine light stabilizers that can be used are, for
example, Tinuvin.RTM. 928 and Tinuvin.RTM.123 or mixtures thereof,
commercially available from Ciba Specialty Chemicals, Tarrytown,
N.Y.
[0056] The coating composition according to the invention can be
applied by known methods. In the case of liquid compositions, they
can be applied, e.g., via commercial spray gun equipment,
preferably by spray gun with a pressured upper container. Solid
compositions can be applied by known electrostatic spraying
processes used for the application of powder coating compositions,
for example, corona or tribo spray guns can be used and other
suitable powder application processes, for example, an aqueous
dispersion of the solid powder composition (aqueous powder slurry)
can be applied or a broad band spreading process can be used to
apply the composition.
[0057] Particularly, the composition according to the invention in
the dry or liquid form can be applied in a dry layer thickness of,
for example, 25 to 30 mils (0.635 to 0.762 mm) regarding a
one-layer application and in a dry film thickness of, for example,
45 to 50 mils (1.143 to 1.27 mm) by a multi-layer deposition of the
coating composition. The final coating thickness can be designed to
be, for example, 60 to 80 mils (1.524 to 2.032 mm) or thicker and
can be built in 25 to 30 mils (0.635 to 0.762 mm) increments per
single application depending on the intended use.
[0058] The applied coating composition according to the invention
can be cured by crosslinking at ambient temperature as well as at
elevated temperature. It is desirable, but not necessarily, to have
a short flash-off phase before start of the curing step at elevated
temperature. The curing temperature can vary from 15 to 100.degree.
C., particularly from 25 to 80.degree. C. The curing times are, for
example, of the order of magnitude of 20 min. to 24 hours.
Preferably the coating composition according to the invention is
crosslinked at ambient temperature in the range of 15 to 35.degree.
C., preferably of 20 to 30.degree. C. in the time range to 24
hours. If forced drying is applied for curing, temperature range 60
to 100.degree. C. is recommended, preferably of 60 to 80.degree.
C., in a time range of 20 to 60 minutes. A hard, crosslinked
surface is obtained with a glossy lacquer-like appearance having
good resistance to chemicals, outstanding mar resistance and very
good optical properties.
[0059] The cured coating can be sanded and/or polished to achieve a
smooth surface of a desired thickness. The coated substrate or
article can be cut into desired shapes.
[0060] The cured surface has a high quality that means
scratch-resistance, stain-resistance, heat-resistance,
chip-resistance and superior hardness. The sanding can be used to
reduce the thickness to a desired value, to obtain a smooth surface
and/or to bring out an aesthetic quality.
[0061] It is possible to replace solid and/or cast materials, such
as, marble or granite slabs, walls, panels and the like by
substrates coated with the coating composition according to the
invention with a high stability and strength as well as a high
weather-proof property with a good heat and stain resistance.
[0062] The coating composition can also be used for store fixtures,
vertical surfacing on substrates of all types and also horizontal
surfacing. It could replace wallpaper. Formulations can be used
outdoors as architectural facings, for example, with a proper UV
stabilization.
[0063] The following examples illustrate the invention. All parts
and percentages are on a weight basis unless otherwise noted.
Molecular weights are determined by gel permeation chromatography
using polymethylmethacrylate as the standard.
EXAMPLES
Example 1
[0064] Preparation of Coating Compositions of the Invention
[0065] Composition 1:
1 Wt. % Part A 1 Desmophen .RTM. A 265 BA (Acrylic polymer with 2%
10.35 of OH groups, 65 wt. % in butyl acetate, manufactured by
Bayer) 2 Desmophen .RTM. 670 BA (Polyester resin with 6.7% 7.75 of
OH groups, 80 wt. % in butyl acetate, manufactured by Bayer) 3
Methyl isobutyl ketone, solvent 14.92 4 Pot-life retarder
(2,4-pentane dione) 1.21 5 Catalyst (1,4-diazabicyclo[2.2.2]octane-
, 33 wt. % in 0.077 dipropylene glycol) 6 Catalyst (100% dibutyltin
dilaurate) 0.003 7 EFKA .RTM.-2022 (Organically modified
polysiloxane in 1.10 solvent mixture, defoamer, manufactured by
EFKA .RTM. Additives, the Netherlands) 8 EFKA .RTM. -3031 (52 wt. %
organically modified poly- 0.29 siloxane in alkyl benzene, leveling
and anticratering agent, manufactured by EFKA .RTM.Additives, the
Netherlands) 9 EFKA .RTM.-4047 (35% wt. % high molecular weight
1.03 modified polyurethane in butyl acetate, dispersing additive,
manufactured by EFKA .RTM. Additives, the Netherlands) 10 Thixatrol
.RTM. Plus (polyamide, rheological additive, 0.28 manufactured by
Elementis) 11 Aerosil .RTM. R972 (Fumed silica hydrophobically
modified 1.45 rheological additive having a BET value of 110
m.sup.2/g, manufactured by Degussa) 12 Aluminum trihydrate, filler
12.91 13 Hindered Amine Light Stabilizer [Bis(1,2,2,6,6- 0.23
pentamethyl-4-piperidyl) sebacate and methyl(1,2,2,6,6-
pentamethyl-4-piperidyl) sebacate] 14 UV absorber
(Methyl-3-[3-(2H-benzotriazol-2-yl)-5- 0.46
tert.butyl-4-hydroxyphenyl]propionate) 15 Corian .RTM. Crunchies
(Ground polymer material of 28.36 polymethymethacrylate filled with
alumina trihydrate and various fillers) Part B Activator
(Hexamethylene diisocyanate isocyanurate, 10.14 19.6% NCO, 90 wt. %
in butyl acetate) Thinner Ethyl acetate 9.44
[0066] Components 1 to 14 are premixed by high-speed disperser and
then ground in bead mill to fineness of grinding 6 of Hegman scale.
The resulting composition is immediately mixed with component
15--ground polymer material.
[0067] Before application, Part A is mixed with Part B in weight
ratio 100:12.6 and thinned by approx. 9 wt. % of Thinner to
application viscosity--flow time 25 seconds using a Ford Cup with
jet diameter 6 mm. Evaluation of the flow time is performed
according to ASTM D-1200 at 25.degree. C.
[0068] Composition 2:
2 Wt. % Part A 1 Potlife retarder (2,4-pentane dione) 2.01 2
Aerosil .RTM. R972 (described above) 0.67 3 Aluminum trihydrate,
filler 27.79 4 Corian .RTM. Crunchies (described above) 11.66 5
Catalyst (1,4-diazabicyclo[2.2.2]octane, 33 wt. % 0.155 in
dipropylene glycol) 6 Catalyst (100% dibutyltin dilaurate) 0.005 7
Desmophen .RTM. A 365 BA/X (acrylic polymer with 2.9% 18.62 of OH
groups, 65 wt. % in butyl acetate/xylene, manufactured by Bayer) 8
Dukon 21 (80 wt. % star polymer with 4.9% of OH 4.95 groups in
butyl acetate, manufactured by Spolek, the Czech Republic) 9 EFKA
.RTM.-2023 (Organically modified polysiloxane in 0.30 solvent
mixture, defoamer, manufactured by EFKA .RTM. Additives, the
Netherlands) 10 EFKA .RTM.-3772 (60 wt. % fluorocarbon modified
0.99 polyacrylate in secondary butanol, leveling and anti-
cratering agent, manufactured by EFKA .RTM. Additives, the
Netherlands) 11 EFKA .RTM.-8530 (100% aliphatic polyether with 1.03
acidic groups, dispersing additive, manufactured by EFKA .RTM.
Additives, the Netherlands) 12 Ethyl acetate, solvent 8.92 13
Thixatrol .RTM. Plus (described above) 0.26 14 Hindered Amine Light
Stabilizer (described above) 0.23 15 UV absorber (described above)
0.46 Part B Activator (described above) 9.51 Thinner Aromatic
hydrocarbon 5.72 Ethyl acetate 5.72
[0069] Components 1 to 15 (except component 4) are premixed by
high-speed disperser and then ground in bead mill to fineness of
grinding 6 of Hegman scale. The resulting composition is
immediately mixed with component 4.
[0070] Before application, Part A is mixed with Part B in weight
ratio 100:12 and thinned by approximately 13 wt. % of Thinner to
application viscosity--flow time 22 seconds using a Ford Cup with
jet diameter 6 mm. Evaluation of the flow time is performed
according to ASTM D-1200 at 25.degree. C.
[0071] Composition 3:
3 Wt. % Part A Duroftal .RTM. VPI 2801 (Polyester with 6.6% OH, 80
wt. 16.65 % in butyl acetate, manufactured by Solutia) Desmophen
.RTM. VP LS 2973 (Aminofunctional polyester reactive thinner, ekv.
weight 396, manufactured by 3.72 Bayer) Butyl acetate, solvent 4.73
Catalyst (1,4-diazabicyclo[2.2.2]octane, 33 wt. % in 0.024
dipropylene glycol) Catalyst (100% dibutyltin dilaurate) 0.006 EFKA
.RTM.-2022 (Defoamer-described above) 1.10 EFKA .RTM.-3772
(Fluorocarbon modified polyacrylate- 0.99 described above) EFKA
.RTM.-4047 (Dispersing additive-described above) 1.03 Hindered
Amine Light Stabilizer (Described above) 0.53 UV absorber
(Described above) 1.10 Thixatrol .RTM. ST (100% castor oil
derivative rheological 0.50 additive) Aerosil .RTM. R972 (Fumed
silica-described above) 0.27 Aluminum trihydrate, filler 21.56
Barium sulfate 6.90 Part B Hexamethylene diisocyanate uretdione
activator 12.63 (100%, 21.8% NCO) Butyl acetate, solvent 5.22
Corian .RTM. Crunchies (described above) 18.20 Thinner Ethyl
acetate 4.84
[0072] All components of Part A are premixed by high-speed
disperser and then ground in bead mill to fineness of grinding 6 of
Hegman scale.
[0073] Part B preparation: Corian.RTM. Crunchies are added in small
amounts to the solution of Activator in butyl acetate and the
mixture is homogenized by high-speed dissolver.
[0074] Before application, Part A is mixed with Part B in weight
ratio 100:61 and thinned by approx. 5 wt. % of Thinner to
application viscosity--flow time 22 seconds using a Ford Cup with
jet diameter 6 mm. Evaluation of the flow time is performed
according to ASTM D-1200 at 25.degree. C.
Example 2
[0075] Application on Plywood Substrate:
[0076] A mixture of both part A and B of Composition 2 from Example
1 is applied by spray gun with pressured upper container and jet
nozzle diameter 2.3 mm on a plywood substrate. The pressure on
spray gun jet nozzle is about 0.2 MPa and the overpressure in upper
container is about 7 kPa. Wet thickness of the first layer should
be maximally 10 mils (0.250 mm) to ensure good adhesion and low
content of entrapped solvents close to the surface. After 1 hour of
drying at ambient temperature the film is force-dried in oven for
one hour at 60.degree. C. The second and the next layers are
sprayed on the force-dried film after the substrate is cooled to
room temperature and the thickness is about 20 to 30 mils (0.508 to
0.762 mm). The resulting film is force dried at 60.degree. C. for 1
hour or can be dried at room temperature for at least 24 hours
before the next layer is applied. When the required thickness is
reached, 60 to 80 mils (1.524 to 2.032 mm), the films are
post-cured at 60 to 80.degree. C. for several hours to accelerate
the hardness development and to improve sandability.
Example 3
[0077] Application on Glazy Ceramic Tiles:
[0078] Commercially available two-pack epoxy primer was mixed with
hardener and thinned to an application viscosity (flow time 18 to
20 seconds at Ford Cup with jet diameter 4 mm). A layer of film is
applied by spraying on the tile substrate with a spray gun having a
jet nozzle diameter of 18 mm and a jet nozzle pressure 0.17 to 0.2
MPa.
[0079] The primer was applied on smooth glazy ceramic tiles in wet
thickness about 0.100 mm. This film was allowed to dry at ambient
temperature for 24 hours.
[0080] The mixture of both part A and B of Composition 1 from
Example 1 was applied by spray gun with pressured upper container
and jet nozzle diameter 2.3 mm. The pressure on spray gun jet
nozzle is about 0.2 MPa and the overpressure in upper container is
about 7 kPa. Each applied layer has a dry film thickness about 20
to 30 mils (0.508 to 0.762 mm).
[0081] The first layer is dried for 1 hour at ambient temperature
and-then the film is force-dried in oven for one hour at 60.degree.
C. The second and the next layers are sprayed on the force-dried
film after the substrate is cooled to room temperature. Forced
drying at 60.degree. C. for 1 hour or room temperature drying for
at least 24 hours is necessary before the next layer is applied.
When the required thickness is reached, 60 to 80 mils (1.524 to
2.032 mm), the coated films are cured at ambient temperature for
several days to achieve appropriate film hardness for good
sandability.
Example 4
[0082] Application on Particle Board Substrate:
[0083] A mixture of both part A and B of Composition 3 from Example
1 is applied by spray gun with pressured upper container and jet
nozzle diameter 2.3 mm on a substrate. The pressure on spray gun
jet nozzle is about 0.2 MPa; the overpressure in upper container is
about 7 kPa.
[0084] Wet thickness of the first layer should be maximally 10 mils
(0.250 mm) to ensure good adhesion and low content of entrapped
solvents close to the surface. After 1 hour of drying at ambient
temperature the film is force-dried in oven for one hour at
60.degree. C. The second and the next layers are sprayed on the
force-dried film after the substrate is cooled to room temperature
and can be thicker--about 20 to 30 mils (0.508 to 0.762 mm). The
film layers are forced dried at 60.degree. C. for 1 hour or can be
dried at room temperature drying for at least 24 hours before the
next layer is applied. When the required thickness is reached 60 to
80 mils (1.524 to 2.032 mm), the coated films are post-cured at 60
to 80.degree. C. for several hours to accelerate the hardness
development and to improve sandability.
* * * * *